Manual mantenimiento Chery A1

Maintenance Manual of Chery A113
(Chassis)
Chery Automobile Co., Ltd

CONTENT
Chapter 1 Brake System .................................................................................................................4
I. System Checking Parameters ..................................................................................................4
1. Check brake disc.....................................................................................................................4
2. Thickness checking.................................................................................................................4
3. Checking of brake friction lining thickness............................................................................4
4. Checking of brake disc run-out ..............................................................................................4
II. Removal/Installation and Overhaul of Front Brake and Brake Calliper...........................5
1. System Structural Diagram.....................................................................................................5
2. Preparations ............................................................................................................................6
3. Notices....................................................................................................................................6
4. Removal and Overhaul ...........................................................................................................6
III. Removal/Installation and Overhaul of Rear Brake ..........................................................10
1. System Structural Diagram...................................................................................................10
2. Preparations ..........................................................................................................................10
3. Notices..................................................................................................................................10
4. Removal Procedure ..............................................................................................................11
4. Installation Procedure...........................................................................................................13
IV. Adjustment and Replacement of Handbrake ....................................................................14
1. System Composition Illustration ..........................................................................................14
2. Preparations ..........................................................................................................................14
3. Notices..................................................................................................................................14
4. Removal/Installation Procedure ...........................................................................................14
Chapter 2 Adjustment of Suspension System and Four-Wheel Alignment ...............................18
I. Removal/Installation and Overhaul of Front Axle and Suspension ...................................18
2. Preparations ..........................................................................................................................20
3. Notices..................................................................................................................................20
4.1 Removal of Shock absorber assembly............................................................................20
4.2 Removal of Control Arm Assembly ...............................................................................21
4.3 Removal of Front Axle Assembly...................................................................................22
II. Removal/Installation and Overhaul of Rear Axle and Suspension ...................................25
2. Preparations ..........................................................................................................................26
3. Notices..................................................................................................................................26
4.1 Removal of Shock Absorber Assembly and Shock Absorber Spring .............................26
4.2 Cross Stay Assembly ......................................................................................................27
4.3 Rear Trailing Arm Assembly..........................................................................................27
4.4. Removal of Rear Axle Assembly...................................................................................28

III. Adjustment of Four-Wheel Alignment ...............................................................................30
1. Adjustment of Front Wheel Toe-In ......................................................................................30
2. Adjustment of Front Wheel Camber Angle..........................................................................30
3. Adjustment of Caster Angle and Kingpin Inclination ..........................................................30
4. Adjustment of Rear-Wheel Alignment Parameters ..............................................................31
IV. Tire Installation and Air Pressure Adjustment.................................................................31
1. Installation of Air Valve.......................................................................................................31
2. Tire Assembling ...................................................................................................................31
3. Tire Inflation.........................................................................................................................32
4. Installation of Wheel and Tire Assembly. ............................................................................32
5. Tightening Method of Wheel Bolts......................................................................................32
6. Installation of Decorative Cover...........................................................................................32
Chapter 3 Removal/Installation and Overhaul of Steering System ............................................33
I. Removal/Installation of Steering Gear..................................................................................33
2. Preparations ..........................................................................................................................34
3. Notices..................................................................................................................................34
II. Removal/Installation of Steering Column ...........................................................................37
2. Preparations ..........................................................................................................................37
3. Notices..................................................................................................................................37
4. Removal Procedure ..............................................................................................................38
III. Adjustment of Steering Gear Clearance ............................................................................44
IV. Adjustment of Power Steering System................................................................................44

Chapter 1 Brake System
I. System Checking Parameters
1. Check brake disc:
The friction surface of brake disc should be flat and has no apparent grooves; otherwise, brake disc should be
replaced.
2. Thickness checking
The standard thickness of front disc (ventilation disc) is 17 mm with its operating limit of 15 mm; when
exceeding the operating limit, the front disc should be replaced.
3. Checking of brake friction lining thickness
Standard thickness of front brake lining shall be 10 mm, application limit shall be 1 mm, and the remaining
thickness of limit brake pad thickness shall be not less than 1mm.
Standard thickness of rear brake lining shall be 5 mm, application limit shall be 1 mm, and the remaining
thickness of limit brake pad thickness shall be not less than 1 mm.
4. Checking of brake disc run-out
Use dial gauge to check the face runout of brake disk, the application limit of front disk shall be 0.03mm, the
application limit of rear disk shall be 0.03mm, otherwise replace it.
Important notice:
After completion of replacing friction lining or brake disk, apply the brake for several times to enable breaking-in
between brake lining and brake disk. Always ensure safety!
After replacing brake lining, check brake fluid level to ensure it is between MIN and MAX.

II. Removal/Installation and Overhaul of Front Brake and Brake Calliper
1. System Structural Diagram
Structural Diagram of Front Brake Assembly
(1) Brake disc positioning bolt (2) Brake disc
(3) Wheel hub bearing unit; (4) ABS speed sensor plug
(5) Dust cover (6) Steering joint
(7) Fixing bolt (8) Friction lining
(9) Friction lining thickness sensor plug (10) Brake bracket
(11) Brake calliper assembly (12) Fixing bolt

2. Preparations
Tools: Ratchet wheel, ratchet lever, 13#, 14#, 16#, 18#, 19#, 8#,
30# socket, 10#, 13#, 14#, 16# ring wrench, vice,
torque wrench, measure ruler..
Accessories: brake fluid
3. Notices
3.1 Please wear necessary labor protection supplies to avoid
accidents.
3.2 The brake liquid is one toxic liquid. In event of contact with the
skin or eyes due to carelessness, flush with a great amount of water
and if necessary call for medical treatment timely.
3.3 The scrapped brake liquid should be accommodated in the
container. It’s prohibited to drain it into the sewage system or stack
with other household garbage.
3.4 Do not depress the brake pedal nor move the vehicle during the
removal/installation operation.
3.5 Do not make the friction lining or brake disc come contact with
the oil substances, which will impair the braking effects.
4. Removal and Overhaul
4.1 Remove the protective cover from the tire rim with slotted
screwdriver.
4.2 Remove the tire fixing nuts with 19# torque wrench or vehicle
attached tool and remove the tire.
Torque: 110±10 Nm.
4.3 Lift the vehicle with elevator.
4.4 Remove the 2 nuts (upper and lower) from
the brake calliper and steering joint with 18# wrench.

4.5 Remove the nuts from brake hose with 13# wrench.
Notice: The brake liquid is one toxic liquid. Do not splash the brake
liquid to the clothes or skin during the removal of the brake hose.
Torque: 16±3 Nm.
4.6 Pull out the brake disc with hand.
4.7 Measure the thickness of friction lining. If below 3mm, replace
timely in pairs.
4.8 Remove the brake calliper and brake pump with 14# wrench.
4.9 Remove the dustproof seal and check for the damage of the
dustproof seal. If necessary, renew the dustproof seal. Clean the
contact surface of the brake piston and apply with one film of
silencing grease.
Notice: It's prohibited to make the dustproof seal come contact with
the silencing grease, which will cause the swelling of the dustproof
seal.

4.10 Remove the piston. Prepare one wood board to hold the piston
and place the wood board between the piston and the wall of the
brake calliper. Press out the piston with the compressed air carefully
through the connecting bore. Place the guard plate (such as hard
wood) at the notch of the brake calliper to protect the piston.
Notice: Do not hold the piston with fingers – danger of clamping!
The brake calliper piston is prohibited from removal at will and
should be removed/installed only by professionals or under the
guidance of the professionals.
4.11 Check the guide sleeve. The guide sleeve should move
smoothly and freely when pushed with hand. Replace the guide
sleeve in event of jamming or stiffness. Notice: Apply the
lubricating grease onto the guide sleeve during assembling.
4.12 Remove the seal ring carefully with the plastic needle, clean the
brake cylinder and components with alcohol and blow dry with
compressed air. Carefully check the surfaces of brake cylinder,
piston, and flange. It’s prohibited to conduct the machining process
on the brake cylinder and piston.
4.3 Installation of brake branch pump: Apply one film of brake
cylinder cream onto the cylinder body, plunger, and seal sleeve.
Attach the seal ring onto the circular groove at the rear of the brake
cylinder. Attach the dustproof seal ring onto the front circular groove
and press it in completely.

4.14 The area between the dustproof seal ring and the brake clamp
housing must be kept dry. It should be kept away from the brake
cylinder cream or the brake liquid, in order to ensure the correct
position of dustproof seal ring.
4.15 Secure the brake piston with the reinforcement parts available
in market and press it onto the dustproof seal ring slightly. Blow the
dustproof seal ring with compressed air (up to 3.0bar) to attach the
piston ring onto the piston.
Notice: Dip the dustproof seal ring and piston with brake
liquid to facilitate the passing of the seal ring.
4.16 (Checking of brake disc) Check the thickness of brake disc.
Replace the brake disc if the thickness is less than the min thickness.
Notice: The two brake discs at the same axle should be replaced at a
time. The friction linings must be replaced following the
replacement of the brake discs.
4.17 Check the max run-out of the end surface of brake disc with
dial gage. If above 0.03mm, replace it. (Provided that the brake disc
thickness is guaranteed, it may conduct the proper machining to
meet with the max run-out.)
4.18 Installation of other portions with reference to the Removal
Procedure.

III. Removal/Installation and Overhaul of Rear Brake
1. Rear brake assembly 2. Brake drum
3. Rear wheel hub bearing assembly 4. Oil seal
5. End cap 6. Bolt
7. Rear wheel sensor 8. Rear brake hose retaining clip
9. Dual-port pipe clip 10. Tie rod
11. Rear shoe pressure spring plate 12. Rear shoe pressure spring
2. Preparations
Tools:
Ratchet wheel, ratchet lever, 10#, 19#, 32# socket, 10# ring wrench,
vice, torque wrench, slotted screwdriver.
Accessories: brake fluid
3. Notices
accidents.
3.2 The brake liquid is one toxic liquid. In event of contact with the
skin or eyes due to carelessness, flush with a great amount of water
and if necessary call for medical treatment timely.
3.3 The scrapped brake liquid should be accommodated in the
container. It’s prohibited to drain it into the sewage system or stack
with other household garbage.
3.4 Do not depress the brake pedal nor move the vehicle during the
removal/installation operation.
3.5 Do not make the friction lining or brake disc come contact with
the oil substances, which will impair the braking effects.

4. Removal Procedure
4.1 Remove the rear wheels (see the removal procedure of front
wheels).
4.2 Remove two position bolts from the brake drum with the cross
screwdriver.
4.3 Remove the bearing dust cap with slotted screwdriver.
4.4 Vibrate the brake drum to remove it.
4.5 Observe the rear braking structure.
4.6 If it’s necessary to check the brake drum bearing, remove the
lock nuts shown in the figure with 30# socket and torque wrench
and remove the brake drum bearing.
Torque: 250±10 Nm

4.7 Remove the handbrake cable with calliper.
4.8 Remove the upper return tension spring with calliper.
4.9 Remove the lower return tension spring with calliper.
4.10 Depress the spring strip of the brake shoe positioning tie rod
with calliper and then rotate clockwise or counter clockwise for 90°
to remove two brake shoe position tie rods.
4.11 Pull out two brake shoes.

4.12 Remove the tension spring to separate the brake shoe.
4.13 In the event of detection of over-tight rear brake, it may adjust
the length of the push rod: Rotate clockwise to eliminate the friction.
4.14 Remove the three bolts shown in the figure with 10# ring
wrench.
4.15 Remove the branch pump and break it down for checking of
intactness.
4. Installation Procedure
Refer to removal procedures.
Bolts
Remove this
tension spring.

IV. Adjustment and Replacement of Handbrake
1. System Composition Illustration
1. Handle 2. Fixing bolts 3. Cable 4, 5. Left/Right rear wheel cable
2. Preparations
Tools: Ratchet wheel, ratchet lever, 10#, 13#, 14#, 16# socket, 10#
13#, 14# ring wrench, vice, torque wrench, slotted screwdriver.
3. Notices
3.1 Please wear necessary labor protection supplies to avoid accidents.
3.2 During the removal/installation of the spring parts, enough cautions should be taken to prevent the ejection
of such parts from causing body injuries.
3.3 The removal/installation at the vicinity of the exhaust pipe must be conducted only after the temperature of
the exhaust pipe is lowered to normal temperature so as to prevent scald.
4. Removal/Installation Procedure
4.1 With reference to the removal/installation of the rear brake,
loosen the handbrake cable of the rear wheels.
To left
rear
brake
assembly
To right
rear
brake
assembly

4.2 Remove the handbrake clip with priers.
Notice: It’s under the rear wheels.
4.3 Remove the fixing bracket bolts of the handbrake cable shown
below with 8# ring wrench.
Torque: 9~12 Nm
4.5 Pry out the protective cover at the handbrake and gear position
with slotted screwdriver.

4.6 Remove all fixing screws from the secondary instrument panel
assembly with ring screwdriver to remove the secondary instrument
panel assembly.
4.7 Remove the handbrake adjustment nuts with 10# wrench.
4.5 Loosen the two handbrake cables with hand.

4.9 Pull out the handbrake cable from the underside of the vehicle
body.
Notice: Remove the handbrake cable at another side in accordance
with the same method.
4.10 (Handbrake adjustment) The length of the handbrake cable
equipped on this model is designed to be the fixed length. To adjust
the handbrake effects, refer to the part “removal of rear brake”. The
adjustment of the ejector rod length (clockwise for looseness and
counter clockwise for tightness) can achieve the handbrake
adjustment.
4.11 The installation procedure should be conducted with reference
to the removal procedure.
Rotate this place

Chapter 2 Adjustment of Suspension System and Four-Wheel
Alignment
I. Removal/Installation and Overhaul of Front Axle and Suspension
The front axle of Chery S21 model adopts the split steering drive axle, with MacPherson independent
suspension. The upper end of the suspension is connected with the vehicle body as the lower end is connected
with the secondary vehicle frame. The front Macpherson suspension undertakes the dual functions of driving
and steering. Subframe connects with vehicle body via elastic element, which improves diving stability and ride
comfort.
Structural diagram of Front Axle and Suspension System

1 Nut 9 Nut 17 Nut
2 Gasket 10 Left control arm 18 Nut
3 Rubber gasket I 10 Right control arm 19 Bolt
4 Rubber gasket II 11 Nut 20 Bolt
5 Left propelling rod weldment assembly 12 Secondary vehicle frame 21 Clamp
5 Right propelling rod weldment assembly 13 Front strut assy. 22 Rubber bush
6 Nut 14 Nut 23 Bolt
7 Bolt 15 Front connecting rod assy. 24 Bolt
8 Bolt 16 Front stabilizer bar 25 Bolt
Composition List for Front Axle and Suspension System

2. Preparations
Tools: 8#, 15#, 18#, 19# socket; 10#, 13#, 15# wrench.
3. Notices
2.2 When carry out maintenance and repair to chassis, please note that whether the safety lock of lifting
machine is locked.
2.3 When carry out removal/installation to shock absorber spring, prevent spring ejection from being injured.
2.4 It’s prohibited to conduct the welding and correction on the bearing components of the wheel suspension
and the guiding components of the wheels.
2.5 During the removal of the chassis component, renew the self-lock nuts and rusted nuts so as to guarantee the
safety.
4.1 Removal of shock absorber assembly
4.1.1 Remove the tire fixing nuts with 19# socket or vehicle attached
wrench to remove the tire (take left side for instance).
Torque: 110±10 Nm
4.1.2 Remove the ABS pipeline from the fixing seat with hand.
4.1.3 Remove the fixing bolts of steering joint and shock absorber
with 18# socket.
Torque: 110±10 Nm

4.1.4 Remove the three fixing bolts of shock absorber assembly
from the vehicle frame with 13# socket.
Torque: 60±5 Nm
4.1.5 Remove the shock absorber assembly.
4.2 Removal of Control Arm Assembly
4.2.1 Remove the fixing bolts of front connecting rod assembly from
the control arm with 15# socket.
Torque: 100±10 Nm
4.2.2 Remove the connecting bolts of front propelling rod and
control arm with 15# wrench.
Torque: 75±5 Nm
4.2.3 Remove the ball joint fixing bolts from control arm and
steering universal joint with 18# socket and 18# ring wrench.
Torque: 100±10 Nm
4.2.4 Remove the connection bolts of control arm and front axle
with 18# socket to remove the control arm assembly.
Torque: 150±10 Nm

4.3 Removal of Front Axle Assembly
4.3.1 Remove the fixing bolts from the chassis mud guard to remove
the mud guard assembly.
Torque: 3±0.5 Nm
4.3.2 Remove the front bracket bolts of the transmission from the
secondary vehicle frame with 19# socket.
Torque: 110±10 Nm
4.3.3 Remove the rear bracket bolts of the transmission from the
secondary vehicle frame with 19# socket.
Torque: 110±10 Nm
4.3.4 Remove the two connecting bolts of front exhaust pipe with
15# socket.
Torque: 50±5 Nm
4.3.54 Remove the two connecting bolts of front exhaust pipe and
rear muffler with 15# socket.
Torque: 50±5 Nm

4.3.6 Remove the fixing bolts at the right side of the booster steering
gear with 13# wrench.
Torque: 75±5 Nm
4.3.7 Remove the fixing bolts at the left side of the booster steering
gear with 15# wrench.
Torque: 75±5 Nm
4.3.8 Remove the fixing bolts of propelling rod and secondary
vehicle frame with 19# socket.
Torque: 105±10 Nm
4.3.9 Remove the fixing bracket of the A/C pipeline from the
secondary vehicle frame with 10# wrench.
Torque: 25±2.5 Nm
4.3.10 Remove the fixing bracket of the condenser from the
secondary vehicle frame with 13# wrench.
Torque: 45±5 Nm

4.3.11 Remove the four connecting nuts of secondary vehicle frame
and vehicle body with 18# socket to remove the front axle assembly.
Torque: 150±10 Nm
4.3.12 Remove the fixing bolts and nuts from the rubber sleeve of
the stabilizer rod with 10# wrench.
Torque: 50±5 Nm
Refer to the removal procedures of front axle and front suspension.

II. Removal/Installation and Overhaul of Rear Axle and Suspension
Structural diagram of Rear Axle and Suspension System
1 Rear trailing arm assembly 7 Rear shaft welding assembly 13 Nut
2 Bolt 8 Cross stay assembly 14 Nut
3 Rear shock absorber assembly 9 Rear spring cushion 15 Bolt
4 Nut 10 Rear bumper block 16 Lock nut
5 Bolt 11 Rear coil spring 17 Rear brake band drum assembly
6 Bolt 12 Nut 18 Bolt

2. Preparations
Tools: 11#, 13#, 15#, 16#, 16#, 19#, 30# socket, Slotted screwdriver,
priers.
3. Notices
accidents.
3.2 Notice to lock the safety lock of the elevator during the repair of
the chassis.
3.3 When carry out removal/installation to shock absorber spring,
prevent spring ejection from being injured.
4.1 Removal of Shock Absorber Assembly and Shock Absorber
Spring.
4.1.1 Remove the tire fixing nuts with 19# torque wrench or vehicle
attached wrench to remove the tire (take left side for instance).
Torque: 110±10 Nm
4.1.2 Remove the connecting bolts of shock absorber assembly and
rear axle with 18# socket.
Torque: 100±10 Nm
4.1.3 Remove the connecting bolts of shock absorber assembly and
vehicle body with 18# socket to remove the shock absorber
assembly.
Torque: 100±10 Nm

4.1.4 Pry out the rear coil spring with screwdriver.
4.1.5 Vibrate from side to side with force with hand to remove the
rear bumper block.
4.2 Cross StayAssembly
4.2.1 Remove the connecting bolts of cross stay and left side of
vehicle body with 16# socket.
Torque: 100±10 Nm
4.2.2 Remove the connecting bolts of cross stay and right side of
vehicle body with 15# socket to remove the cross stay assembly.
Torque: 100±10 Nm
4.3 Rear Trailing Arm Assembly
4.3.1 Remove the connecting bolts from the rear side of rear axle
and trailing arm assembly with 13# socket.
Torque: 100±10 Nm

4.3.2 Remove the connecting bolts from the middle side of rear axle
and trailing arm assembly with 13# socket.
Torque: 100±10 Nm
4.3.3 Remove the connecting bolts of trailing arm and vehicle body
with 15# wrench to remove the rear trailing arm assembly.
Torque: 100±10 Nm
4.4. Removal of Rear Axle Assembly
4.4.1 Remove the connecting bolts of brake pipeline and rear axle
with 11# socket. Notice the storage of brake liquid.
Torque: 16±3 Nm
4.4.2 Remove the rear brake band drum assembly.
4.4.3 Remove the handbrake cable with priers.

4.4.4 Remove the lock nuts from the rear brake band drum assembly
with 30# socket to remove the rear brake band drum assembly.
Torque: 180±10 Nm
4.4.5 Remove the rear axle assembly.
The installation procedure is reverse to that of removal.

III. Adjustment of Four-Wheel Alignment
Please conduct the measurement and adjustment of parameters on
the four-wheel alignment instrument recommended by Chery Auto.
1. Adjustment of Front Wheel Toe-In
The toe-in can be adjusted by means of the optical testing
instrument or mechanical toe-in adjustment instrument.
1.1 Depending on the requirements of the testing instrument,
conduct the pre-adjustment preparations for the wheel alignment;
1.2 Loosen the lock nuts of right steering track rod and the spring
clips of protective sleeve. Based on the demands, rotate the toe-in
adjustment rod to adjust the length, till reach the specified value.
Toe-in value: 6′±6′
1.3 Tighten the lock nuts and install the spring clips of the
protective sleeve. Check if the lock nuts are properly tightened
and the protective sleeve is in right position;
Torque: 35±3 Nm
1.4 At the finish of toe-in adjustment of front wheels, check the
steering wheel for levelness. Otherwise, loosen the lock nuts of the
steering wheel, adjust the steering wheel to level position, and then
tighten the lock nuts of the steering wheel to the specified torque.
2. Adjustment of Front Wheel Camber Angle
2.1 Under normal conditions, it’s unnecessary to adjust the camber
angle after the assembling of independent suspension and wheel
steering joint. In case the wheel camber angle is out of the tolerance
scope due to other reasons, it may be calibrated by means of the
connecting bolts of independent suspension and steering joint.
Front wheel camber angle: 0.87°±50′
2.2 Before the calibration, check (visual observation) the driving
system components for damage and replace the damaged parts.
2.3 In case the front wheel camber angle is out of tolerance,
loosen the connecting bolts of front shock absorber and steering
joint and move the wheels for correction.3. Adjustment of
Caster Angle and Kingpin Inclination
The caster angle and the kingpin inclination are guaranteed by the
designed structure and are free of adjustment during use.

Caster angle: 3.4°±30′
Kingpin inclination: 12.7°If the parameters are out of the specified
range, replace the steering joint.
4. Adjustment of Rear-Wheel Alignment Parameters
All of the rear wheel positional parameters shall be guaranteed
through design process.
4.1 Rear wheel camber angle: 0°±30′
4.2 Rear wheel toe-in: 0°±10′
4.3 If the deformation of rear shaft arising from the great impact
force causes the change of rear wheel alignment parameters that out
of the specified range, correct the rear axle or replace the rear axle.
IV. Tire Installation and Air Pressure
Adjustment
1. Installation of Air Valve
Prior to installing tire valve, firstly check the valve port to ensure
whether it is smooth and free from burr, and then apply glycerol on
the rubber body surface, or soak the tire valve into glycerol. Pull or
press (200 - 400N) using special tools to make the locating ring of
the valve can go through the wheel holes, to this point, the
assembly is completed (soap water is allowed to substitute
glycerol).
2. Tire Assembling
Before fit the tire, apply glycerol or soap water along the cycle of
tire bead, meanwhile, note that:
2.1 When there is colored dot on the wheel rim, align the
uniformity testing mark of tire to the colored dot mark of wheel
rim.
2.2 When without colored dot on the wheel rim, align the dynamic
balance testing mark of tire to valve position.
2.3 When without colored dot on the wheel rim, additionally, there
is no dynamic balance testing mark, however, static balance testing
mark is available, at this point, align the tire valve to the static
balance testing mark.
2.4 The description concerning the uniformity, dynamic balance
and static balance testing marks for tires will be additionally
provided in writing by the product division of Chery Company or
suppliers. In addition, this kind of descriptions will clearly be
indicated on process sheet.

2.5 Carry out tire inflation strictly in accordance with specified
pressure. During inflating process, air pressure shall not exceed
10% of rated pressure. When performing separate packaging to
spare wheel assembly, the rated inflation pressure shall be 3.0bar,
and the spare wheel assembly shall be stored separately from four
wheels. Before the four-wheel alignment, check the air pressure of
all wheels and adjust the air pressure: 2.3bar for front wheels and
2.1bar for rear wheels.
3. Tire Inflation
After completion of tire inflation, screw up the protective cap of
valve, and then carry out dynamic balancing test. Fit appropriate
balance weight at the internal and external fringe of wheel rim as
required. It is required that the unbalancedness of the final
assembly shall be less than 100g·cm, which is approximately
equivalent to a 5g balance weight at the internal and external
fringe of wheel rim. Note: each wheel and each side can use only
one balance weight. Additionally, its maximum mass shall not be
more than 70g. During assembling process, never hit the balance
weight too heavy. Otherwise, replace balance weight in time. In
addition, never use the replaced balance weight again.
4. Installation of Wheel and Tire Assembly.
When fixing wheel and tire assembly, first, manually screw up the
wheel bolt onto the hub for pretension, after that use special tools
for tightening in accordance with diagonal process. Tightening
torque shall be 110±10N.m. It is prohibited to use impact wrench
to prevent from wheel damage, over loose or over tight. It is not
allowed to apply grease on wheel bolt (For new installed wheel
and tire assembly, the wheel bolts should be tightened at first
running of 100km to guarantee the tightening torque. The
tightening torque checking of wheel bolts is one of the items of
regular maintenance)
5. Tightening Method of Wheel Nuts
Tighten the fixing nut in a decussate way, the tightening force shall
be approximately equal, then wheel shall be able to turn freely.
When carry out final tightening, the wheel shall be on the ground.
6. Installation of Decorative Cover
Mount trim cover or place trim cover as required. When fitting clip-
type trim cover, place knock in position by hand or via rubber tools.

Chapter 3 Removal/Installation and Overhaul of Steering System
I. Removal/Installation of Steering Gear
1. Booster steering liquid reservoir 2. Bracket fixing bolt
3. Bracket fixing nut 4. Outlet pipeline
5. Reservoir fixing bracket 6. Steering pump
7. Tensioner 8. Lock nut
9. Adjustment nut 10. Adjustment tie rod
11. Pipe clamp 12. Steering gear
13. Outlet pipeline 14. 15. Fixing bolt
16. Fixing nut 17. Return pipeline

The breakdown illustration of steering gear is shown below:
1 – Lock nuts 2 – Track rod 3 – Input shaft 4 – Left installation bracket 5 – Right installation
bracket
The illustration of steering universal joint and protective sleeve is shown below:
2. Preparations
Tools: 13#, 19# socket wrench, 12#, 13#, 17# non-adjustable wrench.
Accessories: power steering fluid
3. Notices
3.1. Please wear necessary labor insurance products in order to avoid the accidents.
3.2 Avoid steering fluid to contact with skin or eyes when disassembling steering system.
S21-3404060
(Steering universal knuckle
protective sleeve assembly)
1 12 2
3
4 5

4.1 Remove the fixing nuts at the both sides of steering ball joint
with 19# socket.
Torque: 40±5 Nm
4.2 Loosen the fixing nuts under the booster steering hose with 17#
non-adjustable wrench.
Torque: 25±5 Nm
4.3 Loosen the fixing nuts above the booster steering hose with 12#
non-adjustable wrench.
Torque: 25±5 Nm
4.4 Remove the fixing screws above the right bracket of power
steering gear with 13# socket.
Torque: 100±10 Nm
4.5 Remove the fixing screws under the right bracket of power
Torque: 100±10 Nm

4.6 Remove the fixing screws above the left bracket of power
Torque: 100±10 Nm
4.7 Remove the fixing screws under the left bracket of power
Torque: 100±10 Nm
4.8 Remove the fixing bolts of the steering universal joint with 10#
socket wrench to remove the steering gear assembly.

II. Removal/Installation of Steering Column
1 – Steering wheel 2 – Steering column assembly 3 – Steering universal joint assembly
2. Preparations
Tools: Cross screwdriver, 5#, 6# inner hex wrench, 10#, 13#, 22# socket wrench.
3. Notices
3.2 Avoid steering fluid to contact with skin or eyes when disassembling steering system.
3.3 Before disassembling steering wheel, disconnect negative of battery cell to avoid airbag ejection.
Steering Wheel
Steering column assembly
Steering universal joint assembly

4. Removal Procedure
4.1 Loosen the two screws under the steering wheel with 5# inner
hex wrench.
4.2 Remove the horn cover from the steering wheel.
4.3 Remove the fixing nuts of the steering wheel with 22# socket
wrench.
4.4 Remove the steering wheel after screw off the nuts.

4.5 Screw off the two screws from the front surface of combined
switch guard plate with cross screwdriver.
4.6 After screw off the screws, open upward to remove the upper
protective cover.
4.7 Screw off the three screws from the lower side of combined
switch guard plate with cross screwdriver.
4.8 Remove the lower protective cover after screw off the screws.

4.9 Remove the two fixing screws from the combined switch with
cross screwdriver.
4.10 Pull out all plugs from the combined switch. (Total 5 plugs)

4.11 Remove the combined switch.
4.12 Pull out the plug of ignition switch.
4.13 Screw off the fixing screws from ignition lock with 5# inner
hex wrench and remove the ignition lock assembly.

4.14 Screw off the 4 fixing screws from the upper end cap with 6#
inner hex wrench.
4.15 Remove the outer caliper with the outer caliper pliers.
4.16 Remove the retainer and spring with hand.
4.17 Remove the upper end cap with hand.
4.18 Remove the two upper fixing nuts from the steering column
with 13# socket.
Torque: 25±3 Nm

4.19 Remove the two lower fixing nuts from the steering column
with 13# socket.
Torque: 25±3 Nm
4.20 Remove the connecting nuts of steering column and steering
universal joint with 10# socket to remove the steering column
assembly.
Torque: 25±3 Nm
4.21 Remove the connecting bolts of steering universal joint and
steering gear with hand.
Take out steering universal joint assembly.

III. Adjustment of Steering Gear Clearance
1. Place the wheels at linear driving position;
2. Rotate the steering wheel towards both sides;
3. If heard noise of steering gear, adjust the screw as shown in the diagram until no impinge noise is heard
when turning steering wheel;
4. Tighten the screws for further 1/8 turn (approximate 45°);
5. Carry out the road test;
6. If the steering mechanism can not return to the central position by itself, then loosen the bolt for 15°;
7. Carry out the road test.
IV. Adjustment of Power Steering System
1. Correctly connect power steering oil pipe—where the tightening torque for the connector between oil return
pipe, high-pressure oil pipe and steering gear shall be 35±3N.m, the tightening torque of hollow bolt connecting
high-pressure oil pipe and power steering pump shall be 45±3N.m. When filling power steering oil, it is
recommended to use special purpose vacuum pumping oil. The specifications for filling power steering hydraulic
fluid and exhaustion are described as below:
Fill power steering hydraulic fluid into steering reservoir assembly to the maximum level, start engine at
low speed (idle speed) to drive the steering pump, the steering system will be quickly full of hydraulic fluid. In
the oil filling process, only let engine run at idle speed to drive vane pump. Meanwhile, continuously add
hydraulic fluid to prevent vane from sucking air due to oil level drops.
2. When hydraulic fluid in the oil tank presents emulsification state, or the pump emits excessive noise (under
normal condition, max. noise shall be 80 db), it must carry out exhaustion process. The exhaustion procedure is
described as below:
Jack the front part of the vehicle till two front wheels are hung up, start the engine, turn the steering wheel
to right and left till reach limit position (caution: after come to the limit position, try not to stop, even if stop,
never maintain over 2 seconds). Repeat above action for several times, until the air in the system is gradually
exhausted from the oil reservoir. In this process, with the drop of oil level, continuously supplement hydraulic
fluid until the oil comes to specified level.
3. Regularly check and adjust the tension of power steering belt: vertically apply a 100N force at the middle of
the belt, the max. deflection of belt shall be less than 5 mm, otherwise adjust the belt tension until meet the
above requirement via adjusting tension bolt.
Adjustment position调整位置

4. When in service, it is prohibited to turn the steering wheel to limit position, even if it has to do so, never
maintain at this position over 10 seconds. It is strictly prohibited to use power steering pump without oil. If the
driver suddenly feels the steering heavy in service, immediately stop the vehicle, dismantle and repair
accordingly.

Maintenance Manual of Chery A113
(Body Accessories & Dimensions)
After Sales Service Department of Chery Automobile Sales Co., Ltd

CONTENT
Chapter I Front Hood & Trunk.............................................................................................................6
I. Removal and Installation of Front Hood...................................................................................6
1. Preparations ......................................................................................................................6
2. Notes.................................................................................................................................6
3. Removal and Installation of Front Hood Accessories.......................................................6
3.1. Removal Steps...........................................................................................................6
3.2. Installation Steps .......................................................................................................6
4. Removal & Adjustment of of Front Hood Assembly........................................................7
5. Removal and Installation of Air Inlet Grid Assembly ......................................................7
5.1. Removal Steps...........................................................................................................7
6. Removal of Front Hood Lock...........................................................................................8
6.1. Removal Steps...........................................................................................................8
7. Removal & Adjustment of of Hood Cable........................................................................8
7.1. Removal & Adjustment Steps8 .................................................................................8
II. Removal and Installation of Rear Trunk Cover .......................................................................9
1. Preparations ......................................................................................................................9
2. Removal of Rear Decoration Plate ...................................................................................9
3. Removal and Installation of Trunk Lock ........................................................................10
3.1. Removal Steps.........................................................................................................10
3.2. Installation Steps ..................................................................................................... 11
4. Removal of Trunk Lock Cylinder................................................................................... 11
4.1. Removal Steps......................................................................................................... 11
4.2. Installation Steps ..................................................................................................... 11
5. Removal of Rear Wiper Nozzle......................................................................................12
5.1. Removal Steps.........................................................................................................12
5.2. Installation Steps .....................................................................................................13
6. Removal of Rear Wiper Motor .......................................................................................13
6.1. Removal Steps.........................................................................................................13
6.2. Installation Steps .....................................................................................................14
Chapter II Removal and Installation of Trims ....................................................................................15
I. Removal and Installation of Seat Belts ...................................................................................15
1. Preparations ....................................................................................................................15
2. Notes...............................................................................................................................15
3. Removal Steps (Take Driver’s Seat belt as an Example)................................................15
4. Installation Steps.............................................................................................................17
II. Removal and Installation of Seats..........................................................................................17
1. Removal of Front Seats ..................................................................................................17
2. Removal of Rear Seats ...................................................................................................18
III. Removal and Installation of Auxiliary Instrument Panel......................................................19
1. Removal Steps................................................................................................................19
IV. Removal and Installation of Vehicle Carpet..........................................................................22
1. Removal Steps................................................................................................................22
V. Removal of Damping Mat......................................................................................................24
1. Removal Steps................................................................................................................24
Chapter III Removal & Maintenance of Vehicle Doors......................................................................26
I. Removal, Installation & Maintenance of Front Doors ............................................................26
1. System Constitution Diagram.........................................................................................26
2. Preparations ....................................................................................................................26
3. Notes...............................................................................................................................27
4. Removal Steps................................................................................................................27

II. Removal & Installation of Rear Doors ..................................................................................32
1. System Constitution Diagram.........................................................................................32
2. Preparations ....................................................................................................................32
3. Notes...............................................................................................................................33
4. Removal Steps................................................................................................................33
Chapter IV Removal, Installation & Maintenance of Front/Rear Bumper.........................................37
I. Removal, Installation & Maintenance of Front Bumper .........................................................37
1. Preparations ....................................................................................................................37
2. Notes...............................................................................................................................37
3. Removal Steps................................................................................................................37
II. Removal, Installation & Maintenance of Rear Bumper.........................................................39
1. Preparations ....................................................................................................................39
2. Notes...............................................................................................................................39
3. Removal Steps................................................................................................................39
Chapter V Removal and Installation of Headlights Fog Lights & Tail Lights ...................................41
1. Preparations ............................................................................................................................41
2. Notes.......................................................................................................................................41
3. Removal Steps of Headlights..................................................................................................41
3.1. First open the front hood. ....................................................................................................41
4. Removal of Front Fog Lights .................................................................................................44
5. Removal of Tail Lights ...........................................................................................................45
6. Removal of License Plate Lights............................................................................................46
7. Installation & Adjustment of Headlights ................................................................................47
8. Installation & Adjustment of Front Fog Lights ......................................................................48
9. Installation of Tail Lights........................................................................................................48
Chapter VI Removal and Installation of Vehicle Ceiling ...................................................................49
1. Preparations ............................................................................................................................49
2. Notes.......................................................................................................................................49
3. Removal and Installation of Sun Visor...................................................................................49
3.1. Removal Steps.............................................................................................................49
3.2. Installation Steps..........................................................................................................49
4. Removal and Installation of Vehicle-top Armrest...................................................................50
4.1. Removal Steps.............................................................................................................50
5. Removal and Installation of Front Ceiling light .....................................................................51
5.1. Removal Steps.............................................................................................................51
6. Removal and Installation of Reverse Radar Display..............................................................52
6.1. Removal Steps.............................................................................................................52
7. Removal and Installation of A-pillar Shield ...........................................................................52
7.1. Removal Steps.............................................................................................................52
8. Removal and Installation of B-pillar Shield ...........................................................................53
8.1. Removal Steps.............................................................................................................53
9. Removal and Installation of C-pillar Shield ...........................................................................54
9.1. Removal Steps.............................................................................................................54
10. Removal and Installation of Vehicle Ceiling ........................................................................55
10.1. Removal Steps ...........................................................................................................55
10.2. Installation Steps........................................................................................................56
Chapter VII Removal and Installation of Instrument Panel & Instrument Panel crossbeam..............57
I. Removal of Instrument Panel..................................................................................................57
1. Removal Steps................................................................................................................57
3. Methods for Clearing Instrument Maintenance Indicator...............................................66

II. Removal of Instrument Panel crossbeam...............................................................................66
1. Removal Steps................................................................................................................66
Chapter VIII Air Conditioning System...............................................................................................69
I. System Constitution ................................................................................................................69
II. Removal of Evaporator Assembly .........................................................................................69
1. Preparations ....................................................................................................................69
2. Removal and Installation Steps.......................................................................................69
3. Installation of Evaporator Assembly ..............................................................................72
4. Removal and Installation of Interior Evaporator ............................................................72
1. Replacement of Blower..............................................................................................72
2. Removal and Installation of Blower Speed Regulation Module................................74
3. Removal and Installation of Heater Exchanger..........................................................74
4. Removal and Installation of Mode Throttle Related Mechanism ..............................76
5. Removal and Installation of Blend Throttle Related Mechanism ..............................77
6. Removal and Installation of Int./Ext. Throttle Motor & Related Mechanism............78
7. Removal and Installation of Evaporator.....................................................................79
III. Trouble Shooting ..................................................................................................................80
Chapter IX Body Dimension ..............................................................................................................82
I. Basic Instructions on BIW Maintenance.................................................................................82
1. Vehicle Door Structure...................................................................................................83
2. Door panel Maintenance Process....................................................................................83
3. Main Contents of Door Panel Maintenance....................................................................84
4. Basic Methods for Door Panel Maintenance ..................................................................85
4.1. Reconditioning of Dents .........................................................................................85
4.2. Restoration of Stretched Parts.................................................................................87
4.3. Restoration of Cutting & Patching..........................................................................88
4.4. Restoration of Wrinkled Parts .................................................................................89
4.5. Welding of Four Doors and Two Covers.................................................................89
II. Vehicle Body Assembly Dimensions.....................................................................................90
1. Front View ......................................................................................................................90
2. Left-front View...............................................................................................................94
3. Back View.....................................................................................................................103
III. Engine Compartment Dimensions......................................................................................107
IV. Various Opening Dimensions .............................................................................................108
V. Windscreen Dimensions.......................................................................................................108
Chapter X Harness.........................................................................................................................109
Section I Battery Negative Harness..........................................................................................109
I. Harness Sketch..............................................................................................................109
II. Instructions on Main Connectors .................................................................................109
III. Removal and Installation of Battery Harness ............................................................. 110
(I). Preparations............................................................................................................ 110
(II). Notes..................................................................................................................... 110
(III). Removal Steps..................................................................................................... 110
Section II Front Compartment Harness .................................................................................... 111
I. Harness Sketch.............................................................................................................. 111
II. Instructions on Main Connectors ................................................................................. 112
III. Removal and Installation of Front Compartment Harness.......................................... 113
(I). Preparations............................................................................................................ 113
(II). Notes..................................................................................................................... 113
(III). Removal Steps..................................................................................................... 113
Section III Removal and Installation of Electronic Fuel Injection Harness .............................120
I. Harness Sketch..............................................................................................................120
II. Instructions on Harness Connectors.............................................................................121
III. Removal and Installation of Harness..........................................................................123
1. Removal Steps..........................................................................................................123
2. Installation of Harness .............................................................................................128
Section IV In-door harness: ....................................................................................................129
I. Harness Sketch..............................................................................................................129

III. Removal and Installation of In-door harness..............................................................131
(I). Preparations............................................................................................................131
(II). Notes.....................................................................................................................131
(III). Removal Steps.....................................................................................................131
Section V Removal and Installation of Instrument Panel Harness ...........................................141
I. Harness sketch...............................................................................................................141
III. Removal and Installation Instrument Panel Harness ..................................................151
(I). Preparation of Tools ...............................................................................................151
(II). Notes.....................................................................................................................151
(III). Removal and Installation of instrument panel Harness.......................................151
Section VI Left-front Door Harness .........................................................................................154
I. Harness Sketch..............................................................................................................154
III. Removal and Installation of Left-Front Door In-door harness ...................................155
(I). Preparations............................................................................................................155
(II). Notes.....................................................................................................................155
Section VII Right-front Door Harness......................................................................................158
I. Harness Sketch..............................................................................................................158
III. Removal and Installation of Right-front Door In-door harness..................................159
Section VIII Rear Door Harness...............................................................................................160
I. Harness Sketch..............................................................................................................160
III. Removal and Installation of Right-rear Door In-door harness ...................................161
(I). Preparations............................................................................................................161
(II). Notes.....................................................................................................................161
Section IX Tail Door Harness...................................................................................................163
I. Harness Sketch..............................................................................................................163
III. Removal and Installation of Tail Door In-door harness..............................................164
(I). Preparations............................................................................................................164
(II). Notes.....................................................................................................................164
(III). Removal and Installation Steps ...........................................................................164
Section X Defroster Harness ....................................................................................................167
I. Harness Sketch..............................................................................................................167
III. Removal and Installation of Rear Defroster Harness .................................................168
(I). Preparations............................................................................................................168
(II). Notes.....................................................................................................................168
(IV) Installation Steps ..................................................................................................169

Chapter I Front Hood & Trunk
I. Removal and Installation of Front Hood
1. Preparations
Tools: Flat head/cross head screwdriver, socket wrench, snipe nose
pliers
2. Notes
2.1. During removal and installation, be particularly careful to apply
proper strength and no abrupt or violent operation is allowed.
2.2. During removal and installation of the trims, be particularly
careful to avoid surface scratch of them.
3. Removal and Installation of Front Hood Accessories
3.1. Removal Steps
3.1.1. Pull off the detergent
hose.
3.1.2. Press down the water nozzle clip from under the front hood,
and then push it up while removing the noozle outward.
3.2. Installation Steps
The installation steps are reverse to those for removal.

4. Removal & Adjustment of of Front Hood Assembly
Preparation of Tools: 13# sleeve, wheel wrench and extension bar
4.1. Turn and remove the four adjusting bolts off the front hood, and
then the front hood can be taken down. And the positing of the front
hood can be adjusted in all directions by loosening the four
adjusting bolts.
4.2. Installation of Front Hood Assembly:
Installation torque is 29±3Nm
5. Removal and Installation of Air Inlet Grid Assembly
5.1. Removal Steps
5.1.1. Use the wrench to remove the four fastening screws on the Air
Inlet Grid assembly as shown in the picture.
5.1.2. Remove the Air Inlet Grid.
Installation torque is 5±0.5Nm

6. Removal of Front Hood Lock
6.1. Removal Steps
6.1.1. Turn and remove two screws off the front hood to take down
its lock.
6.1.2. Remove the front hood lock cable off the front hood lock
assembly.
7. Removal & Adjustment of of Hood Cable
7.1. Removal & Adjustment of Steps
7.1.1. Remove the plastic nut behind the front hood handle in
driver’s cab.And you can also regulate the cable by adjusting this
nut.

7.1.2. Use snipe nose pliers to remove the front hood cable off the
pull cover.
7.1.3. Drag out the cable.
II. Removal of Rear Trunk Cover
1. Preparations
Tools: flat head screwdriver, 13# sleeve, wrench and cross head
screwdriver
Material(s): Clip
2. Removal of Rear Decoration Plate
2.1. Pry up the rear decoration plate with a flat head screwdriver
before you take it apart.
2.2. Installation of Rear Decoration Plate

3. Removal and Installation of Trunk Lock
3.1. Removal Steps
3.1.1. Remove the pull rod off the upper lock.
3.1.2. Pull off the connector on top of the upper lock.
3.1.3. Use a cross head screwdriver to remove the three screws on
the upper lock.
3.1.4. Remove the trunk lock.

Installation notes: Is the lock column deformed? Is the riveting
adequate? Is the lock jacket on the trunk in good condition? Or can
the lock tongue open and shut freely?
4. Removal of Trunk Lock Cylinder
4.1. Removal Steps
4.1.1. Disengage the hitch bar from the lock core.
4.1.2. Pry open the clip on the lock core with a flat head screwdriver.
4.1.3. Push up the lock core to take it out.
Note: Do not throw away the washer of the lock core.
Pay attention to assemble it to its correct position and joint to door
plate work.

5. Removal of Rear Wiper Nozzle
5.1. Removal Steps
5.1.1. Pry open the shield of the high mount ceiling light with a flat
head screwdriver.
5.1.2. Pull off the connector, and then use a cross head screwdriver
to remove the two screws on the high mount ceiling light and take it
down.
5.1.3. Remove the two nuts on the spoiler with 10# sleeve.

5.1.4. Remove the spoiler.
5.1.5. Pull off the rear water nozzle (You can pry with a flat head
screwdriver, but try to avoid any paint scratch), and then pull off the
water nozzle hose.
Note: Water injection opening should be opposite to wiper motor
steering shaft.
6. Removal of Rear Wiper Motor
6.1. Removal Steps
6.1.1. Remove the rear wiper shield by hand.
6.1.2. Use a 10# sleeve wrench to loosen off the nut above the
motor, and remove the rear wiper blade.

6.1.3. Remove the three fixing bolts on the rear wiper motor.
6.1.4. Remove the motor.

Chapter II Removal of Trims
I. Removal and Installation of Seat belts
1. Preparations
Tools: flat head screwdriver, wrench, sleeve wrench
Spare parts: disposable clip
2. Notes
Keep the seat belts clean and free of oil, and check them for any
damage.
3. Removal Steps (Take Driver’s Seat belt as an Example)
3.1. Carefully pry up the front sill plate with a flat head screwdriver.
3.2. Remove the front door weather strip by hand.
3.3. Remove the B-pillar plate with a flat head screwdriver.

3.4. Remove the decorative covers at the upper and lower ends of
the seat belt with a flat head screwdriver.
3.5. Use a 17# wrench to loosen the upper and lower fastening nuts
before you remove the seat belt.
Installation Torque: 50±5Nm
3.6. Pull off the seat belt warning light connector by hand.

3.7. Use a cross head screwdriver to remove the pre-tension belt
assembly.
4. Installation Steps
Note:
4.1. Keep the seat belt clean and free of oil, and check it for any
damage.
4.2. The pillar shield should fit securely with the vehicle body
without any looseness, and it should also fit well with the vehicle
ceiling and weather strip s.
4.3. The seat belt adjusting slide baffle of the upper B-pillar shield
should be able to move freely and won’t affect the adjustment of the
seat belt, and its fitting clearance with the lower shield should be
consistent and less than 1mm;
4.4. The fitting clearance between the lower B-pillar shield and the
front/rear sill plate should be consistent and less than 1mm;
II. Removal and Installation of Seats
Preparation of Tools: sleeve wrench
1. Removal of Front Seats
1.1. Move the seat by pulling at the movable handle below it, and
when the fixing bolts are shown, use a 13# socket wrench to remove
the bolts in the seat.
Torque: 25±3Nm
1.2. Pull off the seat connector and raise the seat.

2. Removal of Rear Seats
2.1. Use a 13# socket wrench to remove the fixing bolts in the rear
seat cushion.
Torque: 25±3Nm
2.2. There are two rear seat cushions, a left one and a right one,
secured by four bolts respectively.
Torque: 25±3Nm
2.3. The cushion can be dismounted when the four fixing bolts are
removed.
2.4. Pull up the pull button in the rear seat and the seat back can be
released forward (Take the left-rear seat as an example).
2.5. Use a 13# socket wrench to loosen off the two fixing bolts
below the seat back (Take the left-rear seat as an example).
Torque: 25±3Nm

2.6. Open the trunk and take out the trunk vehicle carpet.
2.7. Loosen off the fixing seat of the spare tire and take it out.
2.8. Use a 13# socket wrench to loosen off the fixing bolts in the
rear seat back, and then the rear seat back can be removed.
Torque: 25±3Nm
III. Removal and Installation of auxiliary
Instrument Panel
Preparation of Tools: cross head screwdriver, flat head screwdriver
1. Removal Steps
1.1. Use a flat head screwdriver to pry open the shield at the hand
brake and gears.

2.6. Open the trunk and take out the trunk vehiclepet.
2.7. Loosen off the fixing seat of the spare tire and take it out.
2.8. Use a 13# socket wrench to loosen off the fixing bolts in the
rear seat back, and then the rear seat back can be removed.
Torque: 25±3Nm
III. Removal of auxiliary Instrument Panel
Preparation of Tools: cross head screwdriver, flat head screwdriver
1. Removal Steps
brake and gears.

1.2. Use a cross head screwdriver to loosen off the fixing screws of
the shield
brake and gears.
Note: Please pry carefully.
1.4. Use a cross head screwdriver to remove the two fixing screws
below the shield.
1.5. Take out the gear selector shield upward by hand (The shield
and the auxiliary Instrument Panel are fixed with clips and no fixing
screws are used).

1.6. Use a cross head screwdriver to remove the front fixing screws
of the auxiliary Instrument Panel (One on the left and the other one
the right).
1.7. Use a cross head screwdriver to remove the rear fixing screws
of the auxiliary Instrument Panel (One on the left and the other one
the right), and then the suxiliary Instrument Panel can be
dismounted.
IV. Removal and Installation of Vehicle Carpet
Tools: flat head screwdriver, cross head screwdriver; sleeve wrench
1. Removal Steps
1.1. Dismount the seats. (See Removal of Seat)
1.2. Disassemble the auxiliary Instrument Panel (See Removal of
auxiliary Instrument Panel)
1.3. Remove the seat belt shield. (See Removal of Seat belt)
1.4. Remove the front/rear sill plates, B pillar and the lower shield.

1.5. Use a flat head screwdriver to pry up the top cover of footrest
plate.
1.6. Use a 10# wrench to remove the footrest plate covers
Installation Torque: 7±1N.m
1.7. Remove the rear seat cushion (See Removal of Seats)
Use a cross head screwdriver to remove the left shield of the rear
seat cushion.
1.8. Take down the vehicle vehicle carpet by hand.

2.1. Put the vehicle vehicle carpet inside the vehicle, and take out
the harness connected with the seats, and then press the vehicle
vehicle carpet besideds the middle passage tightly.
2.2. Keep the seat holes visible.
2.3. Spread the vehicle vehicle carpet till it gets to the footrest plate
and press it tightly.
2.4. Spread the left-rear part of the vehicle vehicle carpet according
to the shape of the vehicle floor, keep the installation holes of the
left-rear seats visible, and spread and press the rear part of the
vehicle vehicle carpet according to the shape of the vehicle floor.
V. Removal of Damping Mat
1. Removal Steps
1.1. Remove the vehicle vehicle carpet (See Removal of Vehicle
Vehicle carpet).
1.2. Take down each damping mat.

2.1. The installation steps are reverse to those for removal.
2.2. Notes: When installing, sort out the harness, and at the same
time the damping mat should fit well with the vehicle body plate
work.

Chapter III Removal & Maintenance of Vehicle Doors
I. Removal, Installation & Maintenance of Front Doors
1. System Constitution Diagram
2. Preparations
Tools: flat head screwdriver, cross head screwdriver, 10#, 13# sleeve, wrench and pliers.

3. Notes
3.1. Please wear necessary labour protection supplies to avoid any
accident.
3.2. Disconnect the battery to avoid damaging the eletrical
equipment.
3.3 Use the correct method to disassemble and assemble the glass to
avoid damage.
4. Removal Steps
4.1. Remove the left-front vehicle door weather strip. The fixing clip
of the vehicle door weather strip are “-” shaped, and when
disassembling it, press the weather strip downward, and then push
the weather strip to one side till you can see part of the clip. And go
on to push it to the opposite direction to show another part of it.
Don’t pull the weather strip vertically so as not to damage the
weather strip.
4.2. Use a flat head screwdriver to pry up the plastic decorative
block fixing the rearview mirror outside the vehicle door.
4.3. Use a 10# sleeve wrench to loosen off the two screws fixing the
outside rearview mirror.
4.4. Pull off the electrically-adjustable outside rearview mirror
harness connector and take off the outside rearview mirror assembly.

4.5. Use a cross head screwdriver to loosen off the four screws that
fix the shield inside the door.
4.6. Use a cross head screwdriver to loosen off the screw that fixes
the handle inside the vehicle door.
4.7. Use a flat head screwdriver to pry off the plastic cover of the
screw hole for the handle inside the vehicle door, and then remove
the fixing screw with a cross head screwdriver so as to disassemble
the lock assembly inside the door.

4.8. Pull of the vehicle alarm connector.
4.9. Remove the shield inside the door.
4.10. Pull off the power window up-down switch connector.
4.11. Use a cross head screwdriver to loosen off the two screws of
the front door handle fixing mount.
4.11. Tear off the anti-water plastic sheeting on the left-front door.
4.12. Connect the battery and plug in the window up-down switch
plug, lower the window glass to a proper position and loosen off the
two screws that fix the glass.

4.13. Take out the glass carefully.
4.14. Use a 10# sleeve to loosen off the five screws that fix the
window glass up-down regulator.
4.15. Loosen off the screws, and then pull off the window glass
up-down motor connector to take out the window glass up-down
regulator assembly.

4.16. Use a 10# sleeve wrench to loosen off the two fixing screws
and remove the lock outside the door.
4.17. Use a cross head screwdriver to loosen off the three screws
fixing the lock core and remove it.
4.18. Use a 13# sleeve wrench to loosen off the four fixing screws at
the hinge that fixes the vehicle door, and then the vehicle door can
be disassembled.
Note: The removal steps for the right-front door are the same as
those for the left-front door.

II. Removal & Installation of Rear Doors
1. System Constitution Diagram
2. Preparations
Tools: flat head screwdriver, cross head screwdriver, and 10# / 13# sleeve, wrench.

3. Notes
3.1. Please wear necessary labor protection supplies to avoid
accidents.
3.2. Disconnect the battery so as to avoid damaging the eletrical
equipment.
3.3. Take correct steps during removal and installation of glass to
avoid any damage.
4. Removal Steps
4.1. Disassemble the right-rear door weather strip. The fixing clip of
the vehicle door weather strip are “-” shaped, and when
disassembling it, press the weather strip downward, and then push
the weather strip to one side till you can see part of the clip. And go
on to push it to the opposite direction till another corner of it is
exposed. Don’t pull the weather strip vertically so as not to damage
the weather strip.
fix the shield inside the door.

4.3. Use a flat head screwdriver to pry off the plastic cover of the
screws that fix the handle inside the vehicle door.
4.4. Use a cross head screwdriver to loosen off the screws that
secure the handle inside the door, and then disassemble it.
4.5. Use a cross head screwdriver to loosen off the screws that
secure the handle inside the vehicle door, and then disassemble the
handle inside the door.
4.6. Disassemble the shield inside the door by hand.
4.7. Pull off the power window up-down switch connector.
4.8. Use a cross head screwdriver to remove the two fixing screws in
the mount that fixes the rear door handle cover.

4.9. Tear off the anti-water plastic sheeting on the rear door.
4.10. Connect the battery, lower the window glass to a proper
position and loosen off the two screws that fix the glass, and then
carefully diassemble the glass.
4.11. Use a 10# wrench to loosen off the five screws that fix the
window up-down regulator and remove it.
4.12. Use a 10# sleeve wrench to loosen off the screw that fix the
handle outside the rear door and then remove it.

that fix the rear door lock core and then remove it.
4.14. Use a 13# sleeve wrench to loosen off the four screws (at the
hinge) that fix the right-rear vehicle door and then remove it.
Note: Removal of the left-rear door is similar to that of the right-rear
door.

Chapter IV Removal, Installation & Maintenance of Front/Rear
Bumper
I. Removal, Installation & Maintenance of
Front Bumper
1. Preparations
Tools: 8# wrench, 8#sleeve, cross head screwdriver, flat head
screwdriver
Spare parts: disposable clips
2. Notes
accidents.
2.2. Try to avoid scratching the painted surface of the bumper during
the removal operation.
2.3. For removal in colder environment, operate gently to avoid
damaging the bumper.
3. Removal Steps
(Take the left side as an example)
3.1 Open the Front Hood.
3.2 Remove the headlights. (See Removal and Installation of
Headlights)
3.3 Use a cross head screwdriver to loosen off the four screws on the
grid fence.
3.4. Use a 8# sleeve wrench to loosen off the two bolts on the
bumper and the left wing sheet.
Torque: 11N·m
3.5. Use a cross head screwdriver to loosen off the 7 screws on the
bumper and the front compartment member.

3.6. Use a 8# sleeve wrench and a cross head screwdriver to loosen
off the screws and fixing screws below the mud fender and the
bumper.
Installation Torque: 2±0.5 Nm
3.7 Raise the vehicle with a hoister.
3.8. Use a cross head screwdriver and 8#sleeve to loosen off the
fixing bolts and the screws below the mud fenderand the bumper.
Installation Torque: 2±0.5N.m
3.9. Pull off the fog lights connector.
3.10. Remove the bumper.

II. Removal, Installation & Maintenance of
Rear Bumper
1. Preparations
Tools: cross head screwdriver, flat head screwdriver, No.8 sleeve.
Spare parts: disposable clips.
2. Notes
accidents.
2.2. Try to avoid scratching the painted surface of the bumper when
removing it.
2.3. When removing the bumper in colder environment, operate
gently to avoid damaging it.
3. Removal Steps
3.1 Disassemble the tail lights. (See Removal and Installation of Tail
Lights)
3.2. Open the trunk cover, and use a cross head screwdriver to
loosen off the four fixing clips on the rear bumper.
3.3. Use a cross head screwdriver to loosen off the three clips fixing
the rear bumper bottom and the vehicle body.
Note: Raise the vehicle with a hoister.
3.4 Use an 8# torque wrench to loosen the screws connecting the
wing sheet and the bumper.
Note: Two fixing screws on either side.

3.5 Pull off the connector of the rear license plate lights.
3.6 Disassemble the connector of the reverse radar and remove the
rear bumper assembly.
3.7 Unplug the reverse radar.
3.8 Use a cross head screwdriver to loosen the clip seat of the
reverse radar.
松
紧

Chapter V Removal and Installation of Headlights, Fog Lights & Tail Lights
1. Preparations
Tools: 10# open-ended wrench, cross head screwdriver.
2. Notes
2.1. Please wear necessary labour protection supplies to avoid any
accidents.
2.2. Try to avoid scratching the painted surface of the bumper when
removing it.
2.3. When removing the bumper in colder environment, operate
gently to avoid cracking it.
2.4. When disassembling the headlights, violent operation may
damage their clips on the bumper, so operate properly.
2.5 Pay attention not to scratch the headlight surface when
disassembling and placing it.
3. Removal Steps of Headlights
3.1. First open the front hood.
3.2. Use a 10# open-ended wrench to loosen off the three fixing
screws of the right headlights on the front compartment member.

3.3. Hold the headlight with both hands and apply a forward force to
loosen off the right headlights.
3.4. Unplug the right headlights harness to take out the right
headlights assembly.
3.5. Turn open the the high beam headlight holder shield by hand.
3.6. Press down the bulb fixing clip by hand and turn the clip over to
take out the bulb.

3.7. Unplug the right-front position light harness to take out the
bump.
3.8. Turn open the low beam light holder shield by hand.
3.9. Unplug the low beam light harness.
3.10. Press down the bulb fixing clip by hand and turn the clip over
to take out the bulb.

3.11. Turn the right-front turning light shield counterclockwise to
disassemble the bulb.
(See the above steps for removal of the left headlight)
4. Removal of Front Fog Lights
4.1. Diassemble the bumper assembly. (Refer to removal of bumper)
4.2. Unplug the right-front fog lights harness connector.
4.3. Use a cross head screwdriver to loosen off the three screws that
fix the front fog light, and then disassemble the right-front fog light
assembly
4.4. Turn the right-front fog light holder and remove the bulb.
(See the above steps for removal of left-front fog lights)

5. Removal of Tail Lights
5.1. Open the rear door.
5.2. Use a cross head screwdriver to loosen off the screws fixing the
left tail light.
5.3. Remove the left tail light, unplug the left tail light harness
connector, and then disassemble the left tail light assembly.
fix the tail light holder and open it.

5.5. Turn the bulb counterclockwise by hand and then the bulb can
be removed.
6. Removal of License Plate Lights
6.1. Use a flat head screwdriver to pry off the license plate light.
6.2. Unplug the harness plug to disassemble the license plate light.

7. Installation & Adjustment of Headlights
7.1. Installation Steps for the Headlights
The installation steps of headlights are reverse to those for removal.
7.2. Functions of Headlights
7.2.1. Front view
See right figure:
1 High beam light
2 Position light
3 Low beam light
4 Turn light
7.2.2. Back view
1 High beam light holder
2 High beam adjusting nut
3 Low beam light holder
4 Low beam adjusting nut
5 High beam, low beam, position and turning light plugs
6 Turning light holder
8.3. Adjustment of Headlights
8.3.1 Pay attention to law and regulations and verify the following
items before adjustment:
1). The tire air pressure should comply with the related
standard;
2). Vehicle is unloaded (except for spare tire and equiping
tools, and include driver’s weight for sedan);
3). The vehicle should be parked on level and smooth road or
field;
4). The matched mirror surface of the headlight should be fresh
of dirt;
5). The power supply should work normally and the bulb
should be properly installed.
8.3.2. Insert a cross head screwdriver into related adjusting hole to
adjust the light.
1 2 3 4
5 6
4 3 2
4

8. Installation & Adjustment of Front Fog
Lights
8.1. The installation of front light
The installation steps of front fog light are reverse to those for
removal.
8.2. The adjustment of the front fog lights
The front fog lights can be adjusted by turning the device with your
hand or a cross head screwdriver.
9. Installation of Tail Lights
9.1. Installation steps of the tail lights
The installation steps of tail lights are reverse to those for removal.
9.2. The functions of the tail lights
9.2.1. Front view
See right figure:
1). Left-rear turning light (21w)
2). Brake light (21w)
3). Position light (5-21w)
4). Rear Fog Light (21w)
See right figure:
1). Right-rear turning light (21w)
2). Brake light (21w)
3). Position light (5-21w)
4). Reverse indicator (21w)
3
4
1
2
1
2
3

Chapter VI Removal and Installtion of Vehicle Ceiling
1. Preparations
Tools: sleeve wrench, cross head screwdriver, flat head screwdriver
2. Notes
2.1. During the removal and installtion, make sure to apply proper
force and no violent operation is allowed.
2.2. During removal and installation of the inner decoration parts,
make sure to protect the decoration parts from being scratched.
3. Removal and Installation of Sun Visor
3.1. Removal Steps
3.1.1. Use a cross head screwdriver to loosen off the screws in the
sun visor on the left of the driver’s cab, and disassemble the sun
visor.
As shown in the figure:
Torque: 3±1Nm
3.1.2. The removal steps for the right sun visor are reverse to those
for removal of the left one.

4. Removal and Installation of Vehicle-top
Armrest
4.1. Removal Steps
4.1.1. Open the ceiling armrest screw cover over the co-driver’s seat
by hand, and then use a cross head screwdriver to loosen off the left
and right fixing screws.
As shown in the figure:
Torque: 9±3Nm
4.1.2. Remove the ceiling armrest.
4.1.3. The removal of other ceiling armrests can follow the above
steps.

5. Removal and Installation of Front Ceiling
light
5.1. Removal Steps
5.1.1. Align a flat head screwdriver with the groove along the ceiling
light edge to pry it open, as shown in the figure:
Note: Do not scratch part surface.
5.1.2. Remove the three fixing screws of the the front ceiling light.
Torque: 1.5±0.5Nm
5.1.3. Unplug the harness and disassemble the front ceiling light
assembly.

6． Removal and Installation of Reverse Radar
Display
6.1. Removal Steps
6.1.1. Use a cross head screwdriver to loosen off the screws of the
reverse radar display.
6.1.2. Unplug the harness and remove the reverse radar display.
7. Removal and Installation of A-pillar Shield
7.1. Removal Steps
7.1.1. Use a flat head screwdriver to pry open the weather strip of
the left A-pillar shield, and then take out the left A-pillar shield by
hand.
7.1.2. Take out the left A-pillar shield.

7.1.3. Follow the the removal steps of the right A-pillar shield for
that of the left one.
8. Removal and Installation of B-pillar Shield
8.1. Removal Steps
8.1.1. Disassemble the shield below the left B-pillar (See Removal
and Installation of Seat belt).
8.1.2. Use a flat head screwdriver to pry open the B-pillar shield.
Note: protect the trim part surface from scratching.
8.1.3. Follow the removal steps of the left B-pillar shield for
removal of the right B-pillar shield.

9. Removal and Installation of C-pillar Shield
9.1. Removal Steps
9.1.1. Use a sleeve wrench to loosen off the seat belt bolts (See
Removal and Installation of Rear Seats & Seat belts).
9.1.2. Use a flat head screwdriver to pry open the C-pillar upper
shield.
9.1.3. Remove the C-pillar upper shield.
9.1.4. Please follow the removal steps of left C-pillar upper shield
for that of the right C-pillar upper shield.

10. Removal and Installation of Vehicle Ceiling
10.1. Removal Steps
10.1.1. Disassembling the left/right front sun visors. (See Removal
and Installation of Sun Visor)
10.1.2. Disaasembling the front ceiling light. (Refer to removal and
installation of front ceiling light)
10.1.3. Disassembling all interior ceiling armrests. (See removal and
installation of ceiling armrest)
10.1.4. Disassembling A/B/C-pillar shield. (See removal and
installation of A/B/C-Pillar Shield)
10.1.5. Use a flat head screwdriver to loosen off the vehicle ceiling
clip (4 in all).
10.1.6. Disassemble the four doors’ weather strip by hand.

10.1.7. Open the trunk and disassemble the vehicle ceiling.

Chapter VII Removal and Installation of Instrument Panel &
Instrument Panel Crossbeam
I. Removal of Instrument Panel
Tools: 8 #sleeve, extension bar, 飞扳[MS1], cross head screwdriver,
flat head screwdriver, etc.
1. Removal Steps
1.1. Open the storage box over the console, and use a cross head
screwdriver to loosen off the two screws. Then use a flat head
screwdriver to pry open the storage box. See the right figure:
1.2. Use a cross head screwdriver to loosen off the two screws than
connect the emergency switch with the Instrument Panel, as shown
in the figure:
1.3. Pull out the top part by hand, and then use a flat head
screwdriver to pry open the lower part. Unplug the harness when
removing it, as shown in the figure:

1.4. Use a flat head screwdriver to pry open the control panel of the
airconditioner switch and take it out.
connect the airconditioner switch and the Instrument Panel.
1.6. When taking the airconditioner switch, unplug the two harness
plugs behind it and disassemble the two cables behind the switch.

1.7. Use a 8# sleeve wrench to loosen off the four fixing bolts that
connect the audio system with the Instrument Panel.
1.8. When taking out the audio system, unplug the antenna and
harness.
1.9. Use a cross head screwdriver to loosen off the two screws that
connect the cup-holder and the Instrument Panel, and then take out
the cup-holder.

1.10. Disassemble the auxiliary Instrument Panel (See Chapter I
Removal, Installation & Adjustment of of the Brake System).
1.11. Use a cross head screwdriver to pry open the decoration sheet
on the ash tray and take it out.
connect the cigarette lighter with the Instrument Panel, and unplug
the harness when removing the lighter.
that connects the ashtray with the Instrument Panel and take out the
ashtray.
Note: When disassembling the console, the operations should be
carried out from top to bottom, and you should disassemble the
air-conditioner switch before disassembling the audio system.

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